Dimensionally flexible touch fastener strip

ABSTRACT

A fastening strip for touch fasteners is provided which includes a corrugated portion as well as fastening elements. The corrugated portion allows the strip to be bent in a plane perpendicular as well as parallel with the longitudinal axis of the strip such that it may be applied to curved surfaces and remain substantially flat. Fastening elements such as hooks, loops, mushroom-shaped, bulbous and double hooks may be included on both sides of the strip and on the walls of the channels that form the corrugations as well as between the corrugations. The corrugated fastening strips may be useful for automotive seating and diaper applications. Processes for forming the corrugated fastening strip area also disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.13/185,035, filed on Jul. 18, 2011, which claims the benefit of U.S.Provisional Patent Application 61/364,996, filed Jul. 16, 2010 and U.S.Provisional Application 61/365,724, filed Jul. 19, 2010 and U.S.Provisional Application 61/367,197, filed Jul. 23, 2010, the disclosuresof which are each hereby incorporated herein by reference in theirentireties.

FIELD

The present disclosure relates to the field of touch fasteners,particularly “hook and loop” fasteners and, more specifically, to adimensionally flexible touch fastener strip that may easily be bent inmore than a single plane in order to expand the use beyond substantiallyflat surfaces, and a process for making such.

BACKGROUND

Touch fasteners (i.e. Velcro®, Scotchmate®, Tri-Hook®, etc.) wereoriginally produced using textile technology. Two of the most commontypes of touch fasteners as of this writing are hook and loop fastenersand mushroom and loop fasteners.

Hook and loop type fasteners, as they were originally developed andcommercialized, consisted of a pair of textile strips. These textilestrips could be mated to form a recyclable closure; one of the matesbeing a strip of textile fabric having numerous monofilament fasteningelements, shaped like hooks, projecting from one surface and the othermate being a textile strip with multi-filamented fastening elements,woven into loop shaped projections on one surface. When the matingsurfaces of these strips are pressed together, the numerous hook-shapedelements on one strip were ensnared by the loop elements on the opposingstrip, creating a temporary, recyclable bond. As the strips were peeledapart, the hook elements were deformed resulting in separation from theloop elements, allowing the fasteners to be reused many times.

In the case of mushroom and loop fasteners, the hook type mating stripwas replaced with a strip containing numerous monofilament projectionshaving mushroom shaped heads. The mushroom shaped heads were formed byheating the tips of straight monofilament projections until a bulbous“mushroom head” was formed on each projection. As the strips were peeledapart, the mushroom shaped elements generally deflected and released theloop element, however, the mushroom head would often snap and destroythe loop element, thus reducing the number of times the fastener may bereused.

More recently the use of thermoplastic extrusion/molding methods formaking touch fasteners has become popular. In the case of hook and loopfasteners, the hook strip may now be extruded/molded while the loopstrip may be still produced using woven, knitted or non-woven fabrictechnologies. In the case of mushroom and loop fasteners, the mushroomstrip may be produced by extruding/molding a strip of material havingpin-like projections and then post-forming bulbous mushroom-like headson the pin-like projections; the loop strip still being produced usingwoven, knitted or non-woven technologies.

In some instances, two mating surfaces of mushroom-like heads or bulbsmay be engaged to form a fastener.

The use of extrusion/molding technologies for the production of hooktype and mushroom type touch fasteners has significantly reduced themanufacturing cost and improved the performance and aesthetics of touchfasteners, thus allowing their use in large volume applications, such astab closures on disposable diapers or for the attachment of upholsteryfabrics in automotive type seating.

Both textile and molded touch fasteners are typically produced with aflat or planar base (strip) and numerous projections or loops (fasteningelements) emanating from the top and/or bottom surface of the strip.These fastener strips may typically be sold in strip-like or ribbon-likeform as depicted at 10, 10A in FIG. 1A and FIG. 1B.

In FIG. 1A, the fastener strip 10 is shown as generally planar andcomprises a flat base 12 with a plurality of hook-like 14 ormushroom-shaped (not shown) projections emanating from one surface.

FIG. 1B illustrates the mating strip 10A which is generally planar andcomprises a flat base 12A with a plurality of loops 16 emanating fromone surface. Inverting strip 10 and engaging the surface with theprojections with the loop surface of strip 10A forms a touch fastener.

Various cross sections of typical fastener strips are depicted in FIG.1C through FIG. 1H below.

FIG. 1C illustrates one surface of the base 12 with hook-shapedfasteners 14 projecting therefrom.

FIG. 1D illustrates one surface of the base 12A with loops 16 emanatingtherefrom.

FIG. 1E illustrates hook-shaped fasteners 14 projecting from bothsurfaces of the base 12.

FIG. 1F illustrates loops 16 emanating from both surfaces of the base12A.

FIG. 1G illustrates one surface of the base 12 (or 12A) with hook-shapedfasteners 14 projecting therefrom and loops 16 emanating from theopposite surface.

FIG. 1H illustrates one surface of the base 12 with mushroom-shapedfasteners 18 projecting therefrom.

FIG. 1I illustrates one surface of the base 12 with bulb-shapedfasteners 19 projecting therefrom

While the planar form of the strip that is typical in prior artfastening strips allows the fastening strip to be flexible or compliantwhen bent in a direction generally perpendicular to the surface of thebase as depicted in FIG. 2A, it does not typically allow for complianceor flexing in a generally coplanar direction (or parallel with the planeof the base) as depicted in FIG. 2B.

FIG. 2A illustrates the strip 10 being capable of bending in a planegenerally perpendicular (arrow A) to either surface of the strip 10.

FIG. 2B illustrates that the strip 10 is essentially incapable ofbending in a plane parallel (arrow B) to the surface of the strip 10.

The ability of the fastener strip 10 or 10A to be bent in a geometrygenerally coplanar or parallel to the strip is particularly importantwhen it is desirable to bond or mold the fastener strip to the surfaceof a flat object. Touch fasteners are often bonded to, or otherwiseattached to objects such as room walls, toys, automotive seat cushions,etc. The surface bonded to is often generally flat or planar in nature.Bonding a straight strip of fastener to a flat surface as a simplestraight strip may be relatively straightforward as the strip does nothave to deform significantly to conform to the shape desired. When it isdesirable to attach a fastener strip to a generally flat surface in acurved or otherwise non-straight geometry, the fastener strip istypically cut into small pieces and attached intermittently so as tocreate a form approximating the curve or geometry desired. Curved shapesof fasteners may be cut from large sheets of fastener product, but thisoften is wasteful and requires custom orders, additional inventory andadvanced planning to acquire the various geometries desired.

To allow a touch fastener strip to be bent into a curved geometry, touchfasteners may often be made compliant by cutting the strip-like productintermittently along one or both sides thus producing a backbone likestructure as depicted in FIG. 3A. This allows the product to be bent(arrow C) as required as depicted in FIG. 3B into a curved shape stillhaving a flat surface. In FIGS. 3A and 3B, the projections from thesurface of the strip 10B may be hooks 14, loops 16 or mushroom heads 18or other fastening elements.

Touch fasteners may sometimes be cut into a series of discreet pieces 20and re-joined together with a flexible center spine 22 added to join thepieces together and provide the product 10C as depicted in FIG. 4A. Thisallows the product to be bent and formed (arrow C) into various shapesthat lie in a single plane as required as depicted in FIG. 4B.Variations of this design wherein the discrete pieces and spine areintegrally molded together to produce a strip are contemplated as well.

Another method of providing a flexible strip 10D may include slits orapertures 24 that may be cut into the base 12 of the fastener strip 10Dto make the strip more compliant as depicted in FIG. 5A. This allows theproduct to be bent (arrow C) as required as depicted in FIG. 5B.

Textile fasteners may often be produced with elastomeric fibers woveninto the strip to allow the ribbon-like strip to be stretched, flexed orbent as required by an application.

Although the intermittent cutting of the edges of a fastener strip mayallow it to be more compliant, this is often undesirable when theapplication requires a continuous fastener with a more uniformdistribution of fastening elements along its' length. A typicalapplication that would benefit from this would be the use ofparticularly aggressive and strong fasteners for fastening theupholstery fabric onto automotive seat cushions as depicted in FIG. 6A.In FIG. 6A, a seat 100 for an automobile may include a foam seat cushion102 and a foam seat back 104 in an upright configuration, with aplurality of fastener strips 10 or 10A, mounted to the foam seat surfaceto securely fasten a seat cover 200 to the foam cushion 102, 104.

In this application, one of the fastening elements (the hook side 10 forexample) is molded into or bonded onto the outer surface of a urethaneseat cushion 102. The seat cover 200 is prepared with the matingmaterial (the loop side 10A for example) in the appropriate location formating with the hook-containing strip 10 during assembly of the cover200 to the urethane cushion 102, 104. A cross section of a seat cushiondepicting the hook 10 and loop 10A fastener strips in an overlyingposition ready to be engaged (arrow D) is depicted in FIG. 6B. Thefastening strips may be applied to the urethane cushion as straightstrips (FIG. 6A) or may be applied as curved strips to accommodateaesthetic as well as functional needs as depicted in FIG. 6C.

The fastener strips used for these automotive seating applications areoften molded in place during the casting of the urethane seat cushion byinserting the fastener into the mold before the liquid urethaneprecursors are poured into the foaming mold. The fastener strip maygenerally be non-permeable to prevent the liquid urethane material frompenetrating through the base of the fastening strip and contaminatingthe fastening elements.

The fastening strip closures used for automotive seating are alsosubjected to high use loads by the end user. The forces applied when anend user sits in a seat or moves around in their seat may cause thefastening strip to disengage or tear from the urethane foam seat cushionsurface. It is therefore desirable to distribute these loads over alarge portion of the urethane foam seat cushion surface to avoid tearingthe fastener strip away from the urethane cushion during use. It is alsodesirable to have a high force of fastening using a minimal amount offastener strip to the seat cushion to allow for design flexibility andreduce costs. The use of intermittent or notched fastener strips may notallow for such high forces of fastening. This may be because asignificant amount of the surface of the notched fastener strip, i.e.the gap space in the fastening strip, does not contain fasteningelements. The gaps or intermittent nature of the strip may be furtherundesirable as they reduce the bonding area with the urethane foamthereby reducing the strength of the foam to fastener bond.

Fasteners strips which are non-compliant or poorly comply with thesurfaces being bonded may make the seat cushion stiff in regions localto the fastener strips. This stiffness often telegraphs through the seatcovering thus making the seat uncomfortable to the end user. It istherefore desirable that the fastener strips be compliant in multipleplanes to minimize or eliminate stiff or hard spots in the finishedseat.

Accordingly, a need exists for a cost-effective touch fastener stripthat is flexible in multiple planes yet can maintain the requiredfastening performance. The following disclosure describes such fastenerstrips and the methods for producing them. Although the terms “tape” or“strip” are used throughout the disclosure below, the present inventionis not limited to these configurations for touch fasteners. Although theterms hook and loop fastener and strip are used below, any fastener thatis capable of mechanical fastening is contemplated herein.

SUMMARY

In a first embodiment, the present disclosure relates to a touchfastening strip comprising a base portion having two sides wherein thebase is connected to at least two opposing side walls forming aplurality of channels extending from one side of the base. The stripalso includes a top portion connected to the opposing side walls andfastening elements positioned on one side of the base or on the topportion wherein said strip includes one or more openings in thechannels.

In a second embodiment, the present disclosure relates to a touchfastening strip comprising a planar base having two sides wherein thebase is connected to at least two opposing side walls forming aplurality of channels extending from one side of the base. The fasteningstrip also includes a planar top wall connected to the opposing sidewalls and fastening elements positioned on one side of the base or onthe top wall wherein the opposing side walls as connected to the planartop wall defines an angle of 45° to 179°.

In a third embodiment the present disclosure relates to a method forforming a touch fastening strip comprising supplying polymer materialinto a nip between a molding roll having a corrugated surface includingfastener cavities and a complementary device and forcing the polymermaterial into the corrugated surface and fastener cavities and forming afastener strip. Such fastening strip comprises a base portion having twosides wherein the base is connected to at least two opposing side wallsforming a plurality of channels extending from one side of the base, atop portion connected to the opposing side walls and fastening elementspositioned on one side of the base portion or on the top portion.

In a fourth embodiment the present disclosure relates to a method forforming a touch fastening strip comprising supplying a fastener stripcontaining fasteners and feeding the strip between complementary rollerswherein the rollers include projecting teeth wherein the teeth deformthe fastener strip and provide a fastening strip. The fastening stripcomprises a base portion having two sides wherein the base portion isconnected to at least two opposing side walls forming a plurality ofchannels extending from one side of the base, a top portion connected tothe opposing side walls and fastening elements positioned on one side ofthe base or on the top portion.

In a fifth embodiment the present invention relates to a method forforming a touch fastening strip comprising supplying a fastener stripcontaining fasteners and feeding the strip into a mold having acorrugated surface where vacuum and/or pressure is applied to the stripto form a fastener strip. The fastener strip comprises a base portionhaving two sides wherein the base portion is connected to at least twoopposing side walls forming a plurality of channels extending from oneside of the base portion, a top portion connected to the opposing sideportion and fastening elements positioned on one side of the base or onthe top portion.

In a sixth embodiment, the present disclosure relates to a method offorming a touch fastening strip comprising supplying a fastener stripcontaining fasteners and feeding the strip onto a roller having acorrugated surface where vacuum is applied to the strip to form afastener strip. The fastening strip comprises a base portion having twosides wherein the base portion is connected to at least two opposingside walls forming a plurality of channels extending from one side ofthe base portion, a top portion connected to the opposing side walls andfastening elements positioned on one side of the base or on the topportion.

BRIEF DESCRIPTION OF THE DRAWINGS

The features, operation and advantages of the invention may be betterunderstood from the following detailed description of the preferredembodiments taken in conjunction with the attached drawings, in which

FIG. 1A is a perspective view of a prior art fastener strip for a touchfastener system;

FIG. 1B is a perspective view of a mating prior art strip for a touchfastener system;

FIG. 1C illustrates in cross-section, the fastener strip of FIG. 1A withhook-shaped fasteners projecting from one surface;

FIG. 1D illustrates in cross-section, the fastener strip of FIG. 1B withloops emanating from one surface;

FIG. 1E illustrates in cross-section, the fastener strip of FIG. 1A withhook-shaped fasteners projecting from both surfaces of the base;

FIG. 1F illustrates in cross-section, the fastener strip of FIG. 1Bloops emanating from both surfaces of the base;

FIG. 1G illustrates in cross-section, the fastener strip of FIG. 1A withhook-shaped fasteners projecting from one surface and loops emanatingfrom the opposite surface;

FIG. 1H illustrates in cross-section, the fastener strip of FIG. 1A withmushroom-shaped fasteners projecting from one surface;

FIG. 1I illustrates in cross-section, the fastener strip of FIG. 1A withbulb-shaped fasteners projecting from one surface;

FIG. 2A is a perspective view of the strip of FIG. 1A being capable ofbending in a plane generally perpendicular to either surface of thestrip;

FIG. 2B is a perspective view of the strip of FIG. 1A being essentiallyincapable of bending in a plane generally parallel to the surface of thestrip;

FIG. 3A is a top view of a prior art backbone-like structure forproviding a strip that may be bent in a plane generally parallel to thebase of the strip;

FIG. 3B is a top view of the structure of FIG. 3A bent into a curvedshape and still having a relatively flat surface;

FIG. 4A is a top view of another prior art means of providing astructure that can be bent along the plane of the base structure;

FIG. 4B illustrates the bent shape of the structure of FIG. 4A;

FIG. 5A is a top view of another prior art means of providing astructure that can be bent along the plane of the base structure;

FIG. 5B illustrates the bent shape of the structure of FIG. 5A;

FIG. 6A is a perspective view of an exemplary automotive seat and theuse of touch fastener strips in an automotive foam seat;

FIG. 6B is a cross-sectional view of the use of touch fastener strips toassemble a seat cover to the seat of FIG. 6A;

FIG. 6C illustrates the use of touch fastener strips having a curvedconfiguration in a foam seat;

FIG. 7A is a perspective view of an exemplary corrugated touch fasteningstrip formed with a plurality of channels, according to the presentdisclosure.

FIGS. 7B-7I illustrate cross-sectional views of the corrugated fastenerstrip of FIG. 7A with hook type elements, mushroom type elements, andloop styled elements in various positions on the corrugated strip;

FIGS. 8A-8I are cross-sectional and/or top views of the exemplarycorrugated strip, according to the present disclosure;

FIGS. 9A-9C illustrate the use of the exemplary corrugated fasteningstrip, according to the present disclosure, as a medical wrap or aportion of a medical wrap for the wrist or leg;

FIGS. 10A and 10B illustrate the exemplary corrugated fastener strip,according to the present disclosure, in top and front viewsrespectively, as a closure tab for a diaper, with fastening elementsonly at the end of the closure tab;

FIGS. 10C and 10D illustrate the exemplary corrugated fastener strip,according to the present disclosure, in top and front viewsrespectively, as a closure tab for a diaper with fastening elements onthe top wall of the channels;

FIGS. 10E and 10F illustrate the exemplary corrugated fastener strip,according to the present disclosure, in top and front viewsrespectively, as a closure tab for a diaper with fastening elements inbetween the channels;

FIGS. 11A and 11B are cross-sectional views of the exemplary corrugatedfastener strip, according to the present disclosure, illustratingdifferent portions of the base or the channels having a greater wallthickness than the adjacent wall thickness;

FIG. 12 illustrates in cross-section a high density of corrugationsincluding hook fasteners, according to the present disclosure;

FIG. 13 illustrates in cross-section the use of a protective cover forthe fastening elements, according to the present disclosure;

FIGS. 14A and 14B illustrate in cross-section the attachment of a loopfastener strip to a corrugated strip including hook elements, accordingto the present disclosure, where a force is required for engagement;

FIGS. 15A and 15B illustrate in cross-section that elastomeric fibers orfilms may be integrated into or onto the exemplary corrugated fastenerstrip of the present application;

FIG. 16 is a side view of an exemplary apparatus for forming thecorrugated fastener strip according to the present disclosure;

FIG. 17 is a side view of another exemplary apparatus for forming thecorrugated fastener strip according to the present disclosure;

FIG. 18A is a side view of another exemplary apparatus for forming thecorrugated fastener strip according to the present disclosure; and

FIG. 18B is a side view of an exemplary apparatus for forming thecorrugated fastener strip according to the present disclosure;

FIGS. 19A-D are sectional views of the corrugated fastener strip,according to the present disclosure, including a protective compliantmaterial for the fastening elements;

FIG. 20A is a perspective view of an exemplary corrugated touchfastening strip formed with apertures and notches on the plurality ofchannels, according to the present disclosure.

FIG. 21 is another perspective view of an exemplary corrugated touchfastening strip formed with apertures and notches on the plurality ofchannels, according to the present disclosure.

FIG. 22A-D are additional sectional views of the corrugated fastenerstrip, according to the present disclosure, including a protectivecompliant material for the fastening elements.

DETAILED DESCRIPTION

Still other objects and advantages of the present disclosure will becomereadily apparent to those skilled in the art from the following detaileddescription, wherein it is shown and described preferred embodiments ofthe disclosure. As will be realized, the disclosure is capable of otherand different embodiments, and its several details are capable ofmodification in various respects, without departing from the disclosure.Accordingly, the description is to be regarded as illustrative in natureand not as restrictive.

For elements common to the various embodiments of the presentdisclosure, the numerical reference character between the embodiments isheld constant, but distinguished by the alphanumeric character to theexisting reference character. In other words, for example, an elementreferenced at 10 in the first embodiment is correspondingly referencedat 10A, 10B, and so forth in subsequent embodiments. Thus, where anembodiment uses a reference character to refer to an element, thereference character applies equally, as distinguished by alphanumericcharacter, to the other embodiments where the element is common.

Where a flexible touch fastener product (strip or tape) is desired, thebase 12, 12A of the fastening strip 10, 10A may be shaped with acorrugated type topology. One such exemplary topology is depicted inFIG. 7A.

FIG. 7A is a perspective view of an exemplary corrugated touch fasteningstrip 50 formed with a plurality of channels 52 extending from one sideof the base 12. The channels 52 further include hook elements 14projecting from the top wall 54 of the channel 52. As shown incross-section in FIGS. 7B-7I, other fastening elements known in the art,including, but not limited to, loops 16 and mushroom-shapes 18, may alsobe used on the base 12 and project from any of the surfaces of the baseand/or channels.

The base 12 may be woven, molded or post-formed into the corrugatedshape 50 using various methods as described herein. Fastening elements(mushrooms, hooks, loops, etc. or combinations thereof) may be presentalong all or part of the corrugated surfaces as desired. Severalpossible configurations having fastening elements projecting therefromare depicted in FIG. 7B though FIG. 7I.

By “corrugated” as used herein, it is meant that the base 12 of thestrip 50 is formed into a plurality of channels 52 which may extendoutwardly from one or both sides of the base. (See FIG. 7A.) Suchchannels may be preferably formed perpendicular to the longitudinal axisof the strip. It is contemplated, however, that the plurality ofchannels may be formed at any angle to the longitudinal axis of thestrip, including parallel, perpendicular and all angles in between (e.g.from 1 degrees to 90 degrees in 1 degree increments). Accordingly, thecorrugations may extend in one or more directions, such as in themachine direction, cross-machine direction, angled to machine directionor any combination thereof. Furthermore, the channels may beintermittent or discontinuous lengthwise; i.e. they may start and stopalong their length on a given strip.

Preferably, the plurality of channels are essentially parallel with oneanother as illustrated in FIG. 7A, although it is contemplated that thechannels may also be at an acute angle to one another (<90 degrees). Thechannels may also vary in height and width, one to the next to provideadditional flexibility. By “channel” as used herein, it is meant anelongated shape formed into a base sheet wherein the shape includes twoopposing side walls 56, 58 and, optionally, a top 54 or bottom wall 12located between the side walls. See FIG. 7A. With only two walls, thechannel will resemble a “pleat” while with the presence of a top orbottom wall the channel will resemble a “U”-shape. It is contemplatedthat the side walls may be parallel to one another or angled from eachother laterally and/or longitudinally. The top or bottom wall may beflat, curved or multi-sided (for instance, having two or more straightor curved elements). The base 12 extends between the channels 52interconnecting them.

In other words, channels 52 may be formed in all or only a portion ofthe fastener strip. They may be continuous or intermittent in nature.They may vary in pitch, height, density, angle or shape or anycombination thereof within a single fastener strip 50.

The channels 52 which make up the corrugations may range from about0.001″ or less in amplitude (H) to greater than 0.500″ to permit therequired flexibility such that the strip may be readily bent in a planegenerally parallel to the surface of the strip. See FIG. 8B. Theamplitude H may therefore be in the range of 0.001″ to 2.0 inches. Thewidth (W₁) of the channels 52 and the width between the channels (W₂)may vary from about 0.005″ to about 2.50″ in increments of 0.001″, suchas 0.006″, 0.007″, 0.008″, etc. See FIG. 7A.

Accordingly, the corrugated fastener strip 50 defines an undulatingsurface, as can be readily appreciated by one of skill in the art inview of the description and corresponding figures.

Fastening elements (mushrooms, hooks, loops, etc. or combinationsthereof) may be formed on and projecting from at least portions of one(e.g., a top) or both (e.g., a top and a bottom) of the undulatingsurface (e.g., in one embodiment, surfaces of the channels or betweenthe channels) of the corrugated fastener strip or they may be positionedin specific areas as desired, as can be readily appreciated by one ofskill in the art in view of the description and corresponding figures.

FIG. 7B through FIG. 7I depict exemplary corrugated fasteners with hooktype elements 14, mushroom type elements 18, and loop styled elements 16in various positions on the corrugated strip. These fastening elements,or other fastening elements providing mechanical engagement, may beproduced on one or both faces in a continuous pattern or intermittentfashion.

For instance, FIG. 7B illustrates a corrugated strip 50 having doublehooks 15 projecting only from the top wall of the channel 52. FIG. 7Cillustrates a corrugated strip 50 having hooks 14 projecting from thesides and top wall of the channel 52 as well as from the base 12.

FIG. 7D illustrates a corrugated strip 50 having mushroom-shapedelements 18 projecting in one direction from the top of the channel 52and in the opposite direction from the other side of the base 12 betweenthe channels and not from the walls of the channel.

FIG. 7E illustrates a corrugated strip 50 having mushroom-shapedelements 18 projecting in the same direction from the top wall of thechannel 52 and from the base 12 between the channels. FIG. 7Fillustrates a corrugated strip 50 having loops 16 projecting only fromthe top wall of the channel 52.

FIG. 7G illustrates a corrugated strip 50 having loops 16 projectingfrom the top and side walls of the channel 52 as well as from the base12 between and within the channels. FIG. 7H illustrates a corrugatedstrip 50 having mushroom-shaped elements 18 projecting only from thebase between the channels 52. FIG. 7I illustrates a corrugated strip 50having double hooks 15 projecting only from base 12 between the channels52.

The corrugations allow the product to be bent and/or stretched in aplane that is generally parallel to the plane of the base 12 and thusprovide a fastening strip that can be bent and still remain flat. Thecorrugations allow the fastening strip to be flexible or compliant whenbent in a direction generally perpendicular to the base as depicted inFIG. 8A as well as in generally coplanar directions as depicted in FIG.8B. The corrugations also allow the product to be stretched along thelongitudinal axis of the base as is depicted in FIG. 8C.

FIG. 8A is a side view of the corrugated strip 50 with hooks 14 andillustrates the ease in bending the strip (arrow A) in either directiongenerally perpendicular to the plane of the base 12.

FIG. 8B is a top view of the corrugated strip 50 with hooks 14 andillustrates the ease in bending the strip (arrow B) in either directiongenerally parallel to the plane of the base 12.

FIG. 8C is a top view of the corrugated strip 50 with hooks 14 in anunstretched condition and FIG. 8D illustrates the strip 50 incross-sectional view, unstretched. FIG. 8E is a top view of thecorrugated strip 50 with hooks 14 elongated or stretched (arrow F) in adirection essentially parallel with the longitudinal axis of the strip50. FIG. 8F illustrates in cross-sectional view the strip elongated orstretched (arrow F) in a direction essentially parallel with thelongitudinal axis of the strip 50.

The above referenced bending of the corrugations may be convenientlydefined as shown in FIGS. 8G and 8H. As shown in FIG. 8G, the corrugatedfastening strip including the base 12 having sides 56 and 58 and topwall 54 may define an angle alpha (α) between the base 12 and side walls(56 or 58). As shown in FIG. 8G this angle may have a value of 90° andas shown in FIG. 8H, when the corrugations are stretched, the angle mayincrease in value up to a value of 180° (fully stretched position).Accordingly, the value of the angle alpha (α) may have a value of 90° to180°.

As next shown in FIG. 8I, the angle alpha (α) may have a value of lessthan 90°, and may have a value as low as 45°. Accordingly, the anglealpha (α) formed by the intersection of the planar top wall 12 andplanar side walls 56 or 58 may range from 45° to 180° (fully stretchedposition). Of course, it may be appreciated that the higher the value ofalpha (α) in the as formed fastener will provide a fastener whoseability to stretch is then reduced (i.e. the higher value of alphaalters the geometry of the fastener such that less stretching canoccur). Accordingly, in the non-stretched condition, the value of alpha(α) herein may fall in the range of 45° to 179°.

In addition, reference herein to the feature that the base 12, sidewalls 56 or 58, and top wall 54 may individually or collectively beplanar, may be understood as a wall portion that is relatively flat, andwhich is straight in two dimensions for at least a portion of itssurface.

As may also be evident from FIG. 8I, in those situations where the valueof alpha (α) is less than 90°, the surface 54 of the fastener containingfastening elements 14 now may provide a relatively continuous surface offastening elements when the product is in the unstretched condition.Accordingly, the fastener herein that is formed with plane-like top wall54 and plane-like side walls 56 and 58 may be configured such that theplane-like top wall 54 is configured to provide a nearly continuoussurface of fastening elements. That is, the distance between theplane-like top wall as between channels 52, identified as item 55 inFIG. 8I, may be on the order of 0.001-0.5 inches, more preferably in therange of 0.001-0.25 inches.

It may also be noted that with respect to the materials utilized to formthe fastener configuration illustrated in FIG. 8I, and as discussedfurther herein, the materials are such that they are sufficientlyflexible so that they may be removed from the apparatus the may be usedto continuously form the fastener. See FIG. 16. In such context, thosepolymeric materials that have a flex modulus of less than or equal to400,000 psi may preferably be employed. More preferably, the flexmodulus of the material may be in the range of 75,000 psi to 225,000psi.

It should be noted that the force to extend, stretch or otherwise deformthe fastener herein is significantly less than other fasteners known inthe art (e.g. such as the sinusoidal shaped fastener in U.S. PublicationNo. 2005/0161851). By utilizing planar side walls 56 and 58 the amountof force require to extend, stretch or otherwise deform the fastener isreduced due to the relative ease in bending the planar side walls.Computer modeling of the sinusoidal shaped fasteners compared to thefasteners herein demonstrated about a 20% increase in extension of thefastener over the sinusoidal shaped design, for a given applied force.

The plane-like top surface 12 of the fastener herein also provides asignificant increase in the amount of fastening elements available formating an opposing fastening strip. Relatively few of the fasteningelements on the sinusoidal fastener as reported in the art (see again,U.S. Publ. 2005/0161851) are made available for engagement with opposingfastener elements due to the curvature of the top surface.

As discussed above, the ability to be bent in geometry generallycoplanar to the strip 50 as well as other degrees of freedom isparticularly important when it is desirable to bond or mold the fastenerstrip to the surface of an automotive seat cushion or other non-flatsurface. The corrugated fastener strip 50 by being flexible in multipleplanes allows the fastener strip to stretch or elongate along with thefoam seat bun when a user sits in a seat thereby reducing or eliminatinglocalized stiffness or hard spots in the seat. By choosing anappropriate pitch (height, width, spacing, etc.) for the channels thefastener strength may be maintained at desirable levels.

The corrugated strip 50 may be produced with or without apertures orother cuts if desired so as to maintain a barrier to contaminants suchas liquids or gases encountered in the fastening process. This may provebeneficial if the corrugated products are used in applications, such asthe automotive seating application discussed above, so as to reduce oreliminate the permeation of urethane foam into the fastening elementarea of the strip 50 during molding operations.

The use of a corrugated base as disclosed herein, may also allow theentire fastener (for instance, hooks and base) to be produced from ahigh modulus material if desired, thereby maintaining strong closureperformance while allowing the product to be flexible. This may simplifymanufacturing as well as reduces costs. Accordingly, the corrugatedfastener strips herein may be manufactured from materials that have flexmodulus values up to 500,000 psi.

Corrugated fastener strips may be used to fasten medical wraps which maybe used for supporting sprained wrists, ankles, etc. One such example isdepicted in FIG. 9A. The flexibility and stretchability of thecorrugated fastener strip 50 may provide more user comfort. Thecorrugated fastener strips may be produced with apertures if desired toallow the fastener to breath. It is also contemplated that all or only aportion of the wrap may be corrugated in a continuous and/orintermittent fashion and that all or only a portion of the wrap maycontain fastening elements.

FIG. 9A schematically illustrates a medical wrap 60 for a wrist 70including the corrugated fastener strip 50 of the present disclosure.FIG. 9B is an illustration of a medical wrap 60A for a wrist 70 thatcomprises a corrugated fastener strip 50 having hooks (not shown) on oneside and loops 16 on the other side such that the strip 50 may adhere toitself. FIG. 9C is an illustration of a medical wrap 60B for a leg 80that comprises a corrugated fastener strip 50 having hooks (not shown)on one side and loops 16 on the other side such that the strip 50 mayadhere to itself. A spiral wrap 60B due to the corrugated constructionmay provide a flexible, stretchable material in one direction whileproviding support or structural stiffness in another direction. As notedabove, various combinations of fastening elements may be utilized oneither or both sides of the strip. The corrugated fastener strips and/orwrap may be produced with apertures (see FIG. 10D), if desired, to allowthe strip/wrap to breathe.

When used in applications such as infant diapers or adult incontinenceproducts, touch fasteners may be attached to a “side tab” closure thatthe consumer uses to secure the diaper to the infant or adult. In theseapplications, the flexibility and/or stretchability of a corrugatedfastening tape may eliminate or reduce discomfort to the user. Fasteningtapes disclosed in the art typically do not stretch and therefore may beattached to the disposable garment in combination with elastomericfabrics to enhance the flexibility of the closure. The use ofcorrugations in the base of the fastener strip, as herein disclosed, mayeliminate the need for adding elastomeric fabrics or other materials tothe disposable garment or may be used to supplement the use ofelastomeric fabrics or other materials. Part or all of the fasteningtape may be corrugated as described herein. Some examples of corrugateddiaper tabs are depicted in FIGS. 10A-F. In some cases, the corrugatedstrip 50 may include apertures 94 or otherwise made breathable forapplications such as these. It is also anticipated that a portion of thediaper adjacent to the fastener may also be corrugated and may containfastening elements in or adjacent to the corrugated areas.

FIGS. 10A and B illustrate in top view and front view, a diaper 90including a closure tab 92 formed of a corrugated fastener strip 50 asdisclosed herein, the strip including hook elements 14 (or otherfastening elements) only at the end portion of the base 12 and not onthe channels 52.

FIGS. 10C and D illustrate in top and front view a diaper 90 including aclosure tab 92 formed of a corrugated fastener strip 50 as disclosedherein, the strip including hook elements 14 (or other fasteningelements) at the bottom of the channels and at the end portion of thebase 12.

FIGS. 10E and F illustrate in top and front views a diaper 90 includinga closure tab 92 formed of a corrugated strip 50 as disclosed herein,wherein the fastening elements lie only between the channels 52 withinthe channel to allow for a tactile smooth surface. Upon attachment theforce (arrow G) applied to the tab or stretching of the tab wouldpresent the fastening elements for attachment to a mating surface.

As illustrated in FIGS. 11A and 11B, the thickness of the top 54 (orbottom or sides) wall of the channel 52 in the corrugated regions may beless than, equal to, or greater than the thickness of the base in thebalance of the strip. FIG. 11A illustrates a corrugated strip 50 havinga base 12 and channels 52 with a thicker top wall 54 than the side wallsor base, and double hooks 15 projecting from the thicker wall 54. FIG.11B illustrates a corrugated strip 50 having a base 12 and channels 52with the base being thicker than the walls of the channel and doublehooks 15 projecting from the base 12.

By adjusting the relative thickness of the side walls 56 and 58 to berelatively thinner than the base 12 or top wall 54, the flexibility ofthe fastener herein may be increased while the strength of the interfacewhere the fastening elements attach to the base or top wall, may bemaintained. When a load is applied to the fastening elements it iscommon for the base material to deflect thereby causing the fastener todecouple from the mating elements prematurely. Maintaining the base ortop wall as relatively thicker, where the fastening elements arelocated, may now provide for a relatively stronger fastener whileallowing for a reduction in the amount of material that is necessary toproduce the fastener (i.e. less material use in the relatively thin sidewall sections 56 and 58.

FIG. 12 illustrates in cross-section, that a high density of fasteningelements may be maintained with the channels 52 occupying the valleybetween adjacent fastening elements 15.

In another exemplary embodiment, a film or other protective material 96may be applied to the corrugated fastener strip 50 which may temporarilyshield or protect the fastening elements 15. One such configuration isdepicted in FIG. 13. Touch fastener products for use in automotiveseating applications (see FIGS. 6A-6C) may benefit from the protectivecover 96 during the foam molding operation for the seat cushion. Thecover 96 may protect the fastening elements 15 from contamination duringthe pouring and expansion of urethane precursors in the foaming mold.Provisions may be made for sealing the edges as well as the ends of theprotective cover 96 to the fastener strip, thereby providing protectionfrom contamination in multiple directions during a molding operation.The edges of the corrugated strip may be flat, corrugated or otherwiseshaped to provide a temporary shield.

The protective material may comprise adhesives, foams, gaskets, coatingsor other materials in addition to or in place of a polymeric filmmaterial. If used, the protective film 96 may be removed, melted orotherwise made ineffective subsequent to the molding operation to allowthe fastening elements to be made available for mating with acomplementary fastener strip. In addition it is contemplated that thevalleys 52 a between the channels 52 may be filled with a compliantmaterial that may be removed before engagement with another mating stripor may be compressed to expose the heads of the fastening elements toallow engagement.

As shown in FIG. 19A, a protective material may include a compliantmaterial 70 that may be located along the top of the corrugated strip 50in a manner that partially or fully encapsulates and similarly protectsthe fastener elements 15 but does significantly penetrate into andcontact the base between the fastener elements. In other words, thecorrugated strip 50 may have fastening elements 15 on, for instance, thetop surface 54 of the channels 52 and the compliant material 70 maypartially or totally encapsulate these fastening elements 15 to protectthem from contamination during a molding or other assembly operation. Aportion of the fastener element may protrude through the compliantmaterial so as to allow the fastener to function, in which the case thecompliant material need not be removed. As noted above, the compliantmaterial may be, for instance, a layer of soft foam that may be pressedonto the corrugated strip and allow the fastening elements to penetrateand be protected.

In the case of automotive seating as in FIGS. 6A-C, the molding material(in some cases urethane foam) may penetrate into the channels from thesides (and also thru any apertures in the channels which may help anchorthe strip to the molded product, FIG. 20A). As shown in FIG. 19B, whenthe compliant material 70 is subsequently stripped from the fasteningelements 15 after the molding operation (foam seat 102), numerous hooks15′ may be visible on the surface of the molded seat 102. Fasteningelements may be present in the channels and/or below the channels to aidin the anchoring, but only the top level of fastening elements 15′(those that are to be available for engagement) are preferablyencapsulated or otherwise shielded from contamination during molding.FIGS. 19C and D illustrate the addition of a sheet 72 of crepe,corrugated or other deformable material to the top surface of thecompliant material layer 70 to add strength for stripping the layer fromthe fastening elements 15.

The compliant material 70 may include, but not be limited to, a foamedthermoplastic such as PVC, or thermosetting foam materials, such asurethane foams. The compliant material 70 may contain metallic powdersor other materials that may allow the compliant material to be madeattractive to magnetic forces. Such material may contain magneticmaterials or materials that may be subsequently magnetized to make thecompliant material attractive to other magnetic materials or attractablematerials, such as iron, etc. This may be useful in locating the strip50 to a metal foaming mold such that the strip may be foamed in place.The layer of compliant material may be sufficiently thick to just coverthe fastening elements, for instance, about 0.050 inches thick.

FIG. 20A illustrates that the corrugated strip 50 may include openingssuch as notches 93 and/or apertures 94 to provide additional conformityto a curved surface, such as an automotive seat cushion, and further,may allow the liquid expanding foam mass to anchor the channels to aseat surface. The apertures and notches may be in any or all of thewalls (52, 54, 56) or base 12 or 12A.

The compliant material may be applied to the corrugated strip in such amanner so as to allow the compliant strip to be subsequently removedfrom the corrugated strip in one or more pieces. (FIGS. 19B and D) Thecompliant material may be applied so as to fill the valleys between thechannels 52 and also create a layer of compliant material above the topof the channels 52, thereby creating a continuous surface of compliantmaterial that may allow the compliant material to be removed as one ormore continuous strips.

The corrugated strip may be configured with the compliant materialapplied to the top portion of the corrugated strip so as to encapsulatethe fastening elements located on the top of the channels but notpenetrating significantly into the channels, thus leaving the valleysbetween the channels predominately open. (FIGS. 19A and C) Inapplications where the corrugated strip may be insert-molded, thevalleys between the channels 52 may serve to allow the molded materialto flow in so as to anchor or assist in anchoring the strip to themolded part. As noted above, the channels may be notched or otherwiseapertured and/or may contain fastener elements or have other materialssuch as loop fabric, non-wovens, etc. laminated or attached in somefashion that may serve to enhance anchoring of the corrugated strip intoa molded object.

A flexible, corrugated or otherwise compliant material may be laminatedto, imbedded into or otherwise provided in such a manner, below, on topof or inside the compliant material (FIG. 19C) to assist in the removalof the compliant material or to maintain the integrity of the compliantmaterial as it is stripped from the corrugated strip. See FIG. 19D. Itis anticipated that any protective cover or compliant material maycontain metallic powders or other materials that may allow the compliantmaterial to be made attractive to magnetic forces. Such material mayinclude magnetic materials or materials that may be subsequentlymagnetized to make the compliant material attractive to other magneticmaterials or attractable materials, such as iron, etc.

Attention is directed to FIG. 21 which is similar to FIG. 20A, with thefeature that the fastening strip 50 now preferably includes curvedportions 54 a and 12 a as between wall portions 56 and 58. Accordingly,curved portions 54 a and 12 a may include substantially continuouscurvature. Such a fastening strip may therefore be understood topreferably have a continuous sinusoidal type geometry characterized by asine wave which then repeats along the longitudinal axis of the fastenerstrip. As illustrated, such fastener may again have all of the featuresshown and described above in FIGS. 20A and 19A, 19B, 19C, and 19D. Thisincludes the feature of a protective compliant material 70 that may alsopartially or fully encapsulate and protect the fastening elements 14 or15. It also includes openings such as notches 93 and/or apertures 94.Furthermore, the curved top portion 54 a and/or curved bottom portion 12a may have the differential thickness as compared to the side walls 56and 58 as shown and described above in FIGS. 11A and 11B.

In addition, a pull tab, a die cut or other feature may be incorporatedinto or added to the compliant material to facilitate subsequent removalof the compliant material.

A film or coating or other material may be applied to the corrugatedstrip after forming the corrugated strip to a desired shape, forinstance, curved shape so as to assist in retaining the desired shape.For example, a straight corrugated strip may be bent into a curved shape(FIGS. 8A and 8B) and a film, coating or other material may be appliedto one or more surfaces to allow the strip to retain the new curvedshape. Alternatively, adhesives, heat, ultrasonics, mechanical stakingor other means of securing the corrugated strip in the desired shape maybe employed. It should also be appreciated that the relatively flat base12 may provide an effective bonding surface for attaching a bentcorrugated strip to a substrate using adhesives, ultrasonics or othermethods known to those skilled in the art.

The composition of the compliant material may be modified so as topermit the compliant material to protect the fastening elements duringother types of insert-molding or laminating operations such ascompression molding, injection molding, reaction injection molding,extrusion coating, casting, etc. Although the application for automotiveseating is discussed in this disclosure, it is anticipated that the useof the invention herein disclosed as well as the use of variousprotective techniques disclosed herein may be used for otherapplications within as well as outside the realm of automotive seating.

Fastening elements may be positioned within corrugations so as topartially or fully shield the fastener from premature engagement with amating fastener product. FIG. 14A illustrates in cross-section, acorrugated fastener strip 50 with double hook style fastening elements15 located between channels 52. FIG. 14A further illustrates a loop 16style flat fastening strip 10A positioned adjacent to the corrugatedhook-style fastener strip 50. By positioning the hook style fasteningelements 15 between the channels 52, the loop style elements 16 arerestricted from engaging with the hook style elements 15. Thepositioning of the hook style elements 15 within the corrugations alsomay serve to partially or fully shield the hook style fastening elements15 from unwanted engagement or snagging on other materials that may beprone to engaging with the hook style elements. This may be beneficialfor use on clothing where it is common place for portions of a garmentto inadvertently snag on a hook-style fastener during laundering orduring casual contact with the fastening elements. When the user desiresto make an attachment or mate the corrugated fastener witha-complementary fastener, the user simply applies pressure (arrow E) tothe closure, such as from a finger 110 as illustrated in FIG. 14B,thereby deforming the channels 52 locally, exposing hooking elements 15to the mating fastener elements, loops 16, in this case. FIG. 14Billustrates a loop style flat fastener strip 10A being locally deformedand corrugations 52 being compressed to allow hooking elements 15 toengage loop elements 16. Stretching the strip will also make thefastening elements more available for engagement.

In the case of fasteners that cannot readily be produced or formed intoa corrugated shape, additional materials such as adhesives, coating,films, polymers, may be added to the fastener tape during or prior tothe manufacturing or forming process to enhance the retention of thecorrugations in the finished product. Elastomeric material may be addedto increase the resilience of the product or otherwise provide desiredproperties.

Elastomeric fibers, yarns or other elements may be added to or woveninto the corrugated structure 50 to provide or enhance elastomericproperties or otherwise alter the mechanical properties of thecorrugated strip. FIG. 15A illustrates a textile type corrugatedfastener strip 50A wherein an elastomeric fiber 98 or strip has beenwoven integral with the structure 50. FIG. 15B illustrates a corrugatedfastener strip 50 wherein an layer of, for instance, elastomeric film ora non-woven 96 has been attached to the bottom surface of the corrugatedstrip 50. Without limitation, it is contemplated that elastomericfibers, threads, non-wovens, films, or other substrates may be used toprovide elastomeric enhancement to the corrugated fastener strip 50.

Manufacturing Methods

Corrugations, as described herein, may be molded into or woven into afastener strip 50 during the manufacturing thereof or they may be formedas part of or after the production of the fastener strip. FIG. 16illustrates one exemplary method wherein the corrugated fastener stripmay be integrally formed during the molding operation for a stripincluding fastener elements by forcing molten polymer 200 from anextruder 202 or similar feed device into a nip 212 between a moldingroll 204 having a corrugated surface 206 and fastener cavities 208 and acomplementary roll 210. In this example, the complementary roller 210may include a compliant outer surface 214 which may be used to force thepolymer 200 into the corrugated surface 206 and fastener cavities 208and form the base strip into channels 52 at the same time as the hooks14, or other fastening elements, are formed. A mating roller with acomplementary corrugated outer surface, or other continuous orintermittent method of providing pressure, may also be used in lieu ofthe compliant roller to urge the polymer into the desired geometry andform a base 12 including channels 52 and fastening elements 14, etc.Accordingly, the application of intermittent pressure at the nip whenemploying a complementary roller with the male portion to form thecorrugations may allow for relatively deeper draw and relatively moreprecise geometries. The molding roll and the complementary roll may havecorrugations in the machine direction, cross-machine direction or at anyangle of combination of angles, such as herringbone patterns, etc. Themolding roll and/or the complementary roll may be constructed using aseries of stacked rings or plates as disclosed in U.S. Pat. No.3,312,583; 4,775,310 or 3,752,619, etc. Fastener cavities may bepartially or fully cut through the laminated plates and may be formedusing conventional machining, EDM (electrical discharge machining),chemical etching, laser, electroforming, etc.

Various other methods may be used as well to mold the channels integralwith the fastener strip. Co-extrusions or various web-like materials orfilm-like materials or elastomeric materials may be introduced during orprior to the above molding operation as well. Thermoplastic, plastisols,thermo-set as well as cross-linkable materials and other materials usedin the production of touch fasteners are contemplated. The corrugatedtopology and/or the fastening element may be formed with or without theuse of heat and may be formed using any of the mechanical or chemicalmeans currently available or known to those skilled in the art.

As may be appreciated with reference to FIG. 16, the corrugated fasteneras formed herein, with the formation of plane-like side walls 56 and 58due to stretching, will lead to an increase in the degree of polymerorientation in such walls 56 and 58 as the walls are formed. This thenresults in an increase in the overall tensile strength of the fastener,and in particular, at the side wall locations. This increase in strengthwhen the fastener herein is employed in molded-in applications, such asin automotive seating or other insert-molding operations, provides anincrease in the anchoring strength of the fastener to the selectedsubstrate.

A corrugated fastener strip 50 including channels 52 may be formed bypassing an already formed flat fastener strip 10 from a feed roll 218through a set of complementary “gear-like” rollers 220, 222 asillustrated in FIG. 17. The projecting teeth 224 on the rollers 220, 222deform the strip 10 and form the channels 52 in the strip 50. Thefastening strip 10 a, and/or the rollers 220, 222 may be heated (at 230,for instance) if desired to facilitate the formation of corrugations.Additional materials, such as films, fibers, foils, adhesives, polymers,etc. may be introduced into the nip area 232 of the “gear-like” rollers220, 222 during formation if desired. In some cases a metallic strip 233may be introduced and may be bonded to the fastener strip during thecorrugation process. The attachment of a metallic strip 233 to thecorrugated fastener may permit the corrugated fastener to be bent into adesirable shape and retain that shape. The metallic strip 233 may alsoserve to allow the corrugated fastener strip to be made magneticallyattractive. This may be beneficial for applications such as automotiveseating wherein it is common practice to temporarily affix the fasteningstrip in a seat cushion mold using magnets preinstalled in the moldsurface.

Corrugated fastener strips 50 may be formed by thermoforming (or vacuumforming) channels 52 into a flat fastener strip 10A. FIG. 18Aillustrates an example of an intermittent method for forming channels 52and FIG. 18B illustrates an exemplary continuous method for formingchannels in a flat strip 10A. In FIG. 18A, a flat fastener strip 10A maybe supplied from a feed roll 218 and into a foraminous mold 240 having acorrugated surface 242 where a vacuum (and/or pressure) may be appliedto the strip to force the strip to conform to the corrugated surface ofthe mold and form channels 52 in the strip. The result is a corrugatedfastener strip 50 including fastener elements 14, for example. Thefastener strip 10A may be heated prior to forming (230) or duringforming in the corrugated mold, and assisted by vacuum or a pressuredifferential or other method known to those skilled in the art.

In FIG. 18B, a continuous method of forming is illustrated, wherein aflat fastener strip 10A may be supplied from a feed roll 218 and over aroller 244 having a corrugated outer surface 246 and including means fordrawing a vacuum over the roller 244 (porous, foraminous, etc.). Thevacuum (or pressure) may be applied to the strip to force the strip toconform to the corrugated surface of the mold and form channels 52 inthe strip. The result is a corrugated fastener strip 50 includingfastener elements 14, for example. The fastener strip 10A may be heated(230) prior to forming or during forming in the corrugated mold.

This disclosure further contemplates and includes the use of commonlyowned U.S. application Ser. No. 12/690,700 filed Jan. 20, 2010, theteachings of which are included herein in their entirety and whichapplication is attached hereto.

In all embodiments described above as well as other configurationscontemplated by this disclosure, it is contemplated that the fastenerstrip 50 may have areas that are corrugated with or without fasteningelements. It is further contemplated that all or only a portion of thefastener strip may be corrugated, that corrugations may be uniform ornon-uniform in nature, that the fastener strip may be straight or curvedor any combination of such, that the fastener strip may retain a shapewhen deformed or may be somewhat resilient and may return to a preferredshape after temporary deformation.

While particular embodiments of the present disclosure have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the disclosure. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this disclosure.

What is claimed is:
 1. A method for forming a touch fastening stripcomprising: placing a material adjacent a corrugated surface; forcingthe material against the corrugated surface to form a corrugated stripdefining an undulating surface having a plurality of channels and a baseportion between adjacent channels, the corrugated strip defining aplane, the corrugated strip formed to be bendable within the plane andout of the plane, such that when the corrugated strip bends within theplane, the corrugated strip remains in the plane; and providingfastening elements on and projecting from at least portions of a top ofthe undulating surface, wherein placing a material adjacent a corrugatedsurface comprises placing the material between first and secondsurfaces, at least one of the first and second surfaces having thecorrugated surface.
 2. The method of claim 1, further comprising formingone or more openings through the corrugated strip in the base portion.3. The method of claim 1, wherein placing a material adjacent acorrugated surface comprises placing, adjacent the corrugated surface, astrip of material having one or more openings therethough.
 4. The methodof claim 1, wherein providing fastening elements on and projecting fromat least portions of a top of the undulating surface comprises formingfastening elements on and projecting from at least portions of a top ofthe undulating surface during forcing the material against thecorrugated surface.
 5. The method of claim 1, wherein placing a materialadjacent a corrugated surface comprises placing a strip of materialadjacent the corrugated surface.
 6. The method of claim 1, whereinplacing a material adjacent a corrugated surface comprises placing,adjacent the corrugated surface, a strip of material having fasteningelements on and projecting from at least portions of a top surfacethereof.
 7. The method of claim 1, wherein placing a material betweenfirst and second surfaces comprises placing a molten material betweenfirst and second surfaces.
 8. The method of claim 1, wherein placing amaterial between first and second surfaces comprises supplying polymermaterial into a nip between a molding roll having a corrugated surfaceand fastener cavities and a complementary device, and wherein providingfastening elements on and projecting from at least portions of a top ofthe undulating surface comprises forcing the polymer material into thefastener cavities to form the fastening elements.
 9. The method of claim1, wherein placing a material adjacent a corrugated surface comprisesplacing a touch fastening strip containing fastening elements adjacentthe corrugated surface and wherein forcing the material against thecorrugated surface comprises applying vacuum and/or pressure to thetouch fastening strip to force the touch fastening strip against thecorrugated surface to form a corrugated touch fastening strip.
 10. Themethod of claim 1, wherein placing the material between first and secondsurfaces comprises placing a touch fastening strip containing fasteningelements onto a roller having a corrugated surface.
 11. The method ofclaim 1, wherein providing fastening elements on and projecting from atleast portions of a top of the undulating surface comprises applying aremovable protective material to at least a portion of the fasteningelements to temporarily shield the fastening elements.
 12. The method ofclaim 1, wherein providing fastening elements on and projecting from atleast portions of a top of the undulating surface comprises providing aremovable protective material to at least a portion of the fasteningelements to temporarily shield the fastening elements.
 13. The method ofclaim 12, wherein providing a removable protective material to at leasta portion of the fastening elements to temporarily shield the fasteningelements comprises providing a removable protective material that doesnot contact a top surface of the corrugated strip in the base portion.14. The method of claim 12, wherein providing a removable protectivematerial to at least a portion of the fastening elements to temporarilyshield the fastening elements comprises providing a removable protectivematerial that encapsulates at least a portion of the fastening elementsto temporarily shield the fastening elements.
 15. The method of claim12, wherein providing a removable protective material to at least aportion of the fastening elements to temporarily shield the fasteningelements comprises providing a removable protective material comprisinga metallic material.
 16. The method of claim 1, further comprisingapplying a protective material to shield the fastening elements.
 17. Themethod of claim 1, further comprising providing a metallic material thatcooperates with the corrugated strip.
 18. The method of claim 17,further comprising introducing the metallic material against thecorrugated surface to form the corrugated strip with the metallicmaterial.
 19. The method of claim 1, wherein forcing the materialagainst the corrugated surface to form a corrugated strip defining anundulating surface having a plurality of channels and a base portionbetween adjacent channels comprises forming the plurality of channels toextends across a width of the corrugated strip.
 20. The method of claim1, wherein providing fastening elements on and projecting from at leastportions of a top of the undulating surface comprises providingfastening elements on and projecting from a top surface of the channelsand a top surface of the base portion.
 21. The method of claim 1,wherein forcing the material against the corrugated surface to form acorrugated strip defining an undulating surface having a plurality ofchannels and a base portion between adjacent channels comprises forcinga portion of the material against the corrugated surface to form apartially corrugated strip.
 22. The method of claim 1, furthercomprising applying heat to at least one of the material and thecorrugated surface to facilitate formation of the corrugated strip. 23.The method of claim 1, further comprising applying heat to at least oneof the material, the first surface and the second surface to facilitateformation of the corrugated strip.
 24. The method of claim 1, furthercomprising applying the corrugated strip to a diaper tab.
 25. The methodof claim 1, further comprising applying the corrugated strip to anautomotive seat cushion.
 26. A method for forming a touch fasteningstrip comprising: placing a material adjacent a corrugated surface;forcing the material against the corrugated surface to form a corrugatedstrip defining an undulating surface having a plurality of channels anda base portion between adjacent channels, the corrugated strip defininga plane, the corrugated strip formed to be bendable within the plane andout of the plane, such that when the corrugated strip bends within theplane, the corrugated strip remains in the plane; and providingfastening elements on and projecting from at least portions of a top ofthe undulating surface, wherein forcing the material against thecorrugated surface to form a corrugated strip defining an undulatingsurface having a plurality of channels and a base portion betweenadjacent channels comprises forcing the material against the corrugatedsurface to form a corrugated strip having at least some of the channelsformed with a planar top wall and a first planar side wall connected tothe planar top and an opposing second planar side wall connected to theplanar top wall.
 27. A method of securing an automotive seat cover to aseat cushion comprising: placing a corrugated fastener strip in a seatcushion mold, the corrugated strip defining an undulating surface havinga plurality of channels and a base portion between adjacent channels,the corrugated strip defining a plane, the corrugated strip formed to bebendable within the plane and out of the plane, such that when thecorrugated strip bends within the plane, the corrugated strip remains inthe plane, the corrugated fastener strip having fastening elements onand projecting from at least portions of a top of the undulatingsurface; placing a foaming material in the seat cushion mold to createthe seat cushion where the corrugated strip becomes embedded in thefoam; and securing a mating fastener disposed on the seat cover to thecorrugated fastener strip to secure the seat cover to the seat cushion,further comprising bending the corrugated strip within the plane, andwherein placing a foaming material in the seat cushion mold to createthe seat cushion where the corrugated strip becomes embedded in the foamcomprises placing the foaming material in the seat cushion mold tocreate the seat cushion where the corrugated strip becomes embedded inthe foam in its bent configuration.
 28. The method of claim 27, whereinplacing a corrugated fastener strip in a seat cushion mold comprisesplacing, in a seat cushion mold, a corrugated fastener strip having oneor more openings through the base portion.
 29. The method of claim 27,further comprising providing a removable protective material totemporarily shield the fastening elements.
 30. The method of claim 29,wherein providing a removable protective material to temporarily shieldthe fastening elements comprises providing a removable protectivematerial to at least a portion of the fastening elements to temporarilyshield the fastening elements and that does not contact a top surface ofthe corrugated strip in the base portion.
 31. The method of claim 29,wherein providing a removable protective material to at least a portionof the fastening elements to temporarily shield the fastening elementscomprises providing a removable protective material that encapsulates atleast a portion of the fastening elements to temporarily shield thefastening elements.
 32. The method of claim 29, wherein providing aremovable protective material comprises providing a removable protectivematerial comprising a metallic material.
 33. The method of claim 27,further comprising applying a protective material to shield thefastening elements.
 34. The method of claim 27, further comprisingproviding a metallic material that cooperates with the corrugated strip.